Art of manufacturing articles from pulp materials.



No. 660,644. Patented Oct. 30, I900.

J. M. LEAVER.

ART OF MANUFACTURING ARTICLES FROM PULP MATERIALS. (Application filed Nuv. 8, 1899.)

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JanzesflLem/er; 3w Witt Lama 97 I M A flttozm m: "cams PETE-NS co. PHOYOAJYHC. wammmon n c No. 660,544. Patented Oct. 30, I900. J. M. LEAVER.

ART OF MANUFACTURING ARTICLES FROM PULP MATERIALS.

(Application filed Nov. 8, 1899.]

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anon mg limes/71 .Leauer; amzwt'oi )bitneoow No. 660,644 Patented Oct. 30, won.

L m. mum ART 0F MAKUFAQTUZ'MIIG KME'EQEES FRO! PULP MATERIALS.

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Z40 Z5 3g 25 a as as 24 6- Jains lfleav UNTTED STATES PATENT OFFICE.

JAMES MARSHALL LEAVER, OF BAY MILLS, MICHIGAN, ASSIGNOR TO LEWIS A. HALL AND ROBERT H. MUNSON, OF SAME PLACE.

ART OF MANUFACTURING ARTICLES FROM PULP MATERIALS.

SPECIFICATION forming part of Letters Patent No. 660,644. dated October 30, 1906.

Application filed November 8| 1899- Eerial No. 736,278- (No specimens.)

To all whom it may concern: analogous structures-and at the same time Be it known that I, JAMES MARSHALL LEA- baking the articles and imparting thereto VER, a citizen of the United States, residing any desired configuration or ornamentation at Bay Mills, in the county of Chippewa and in substantially a single operation.

State of Michigan, have invented a new and \Vhile the fundamental features of the useful Art of Manufacturing Articles from process are necessarilysusceptible to modifi- Pulp Materials, of which the following is a cation and various forms of apparatus may specification. be resorted to for carrying the process into This invention relates to the art of manueifect without departing from the spirit or IO facturing articles from pulp materials, and principle thereof, still for illustrative purhas special reference to the manufacture of poses a preferable form of apparatus is shown doors, shutters,.sasl1, blinds, window-frames, in the accompanying drawings, in whichdoor-frames, furniture, interior finish for Figure 1 is a plan view of thepreferred houses, and other products or articles of a form of apparatus utilized in carrying out 15 like nature. the invention. Fig. 2is an end view thereof.

To this end the invention primarily con- Fig. 3 is a longitudinal sectional view on the templates a simple and eflicient means for line 3 3 of Fig. 1. Fig. 4 is a similar view on manufacturing ina cheap and practical manthe line 4 40f Fig. 1. Fig. 5 is a cross-secner articles from pulp materials which'are tional view on the line 5 5 of Fig. 1. Fig. 6 7o 20 ordinarily constructed entirely of wood or of is a plan view, partly in section, of a door pulp and has specially in View the production made from pulp materials illustrating a form of substantially solid articles or products in of article that can be manufactured by the coutradistinction to articles composed. of process. Fig. 7 is a plan view of the form of sheets of pulp or sheets of pulp in combinacore which is utilized in constructing a door 25 tion with a wooden core, andin the construcfrom pulp materials. Fig. 8 is a cross-section of which articles the sheets, suitablyemtional view on the line 8 8 of Fig. 6. bossed or ornamented, are attached to each Like numerals of reference designate corother and also to the core. This construcresponding parts in the several figures of the' tion of article-is now known in the art; but drawings. 30 in the manufacture of sheets of pulp mate- The presentinvention does notcontemplate rial considerable expense is necessarily inthe formation of doors and analogous strucvolved, inasmuch as the sheets have to be tures entirely from pulp material, as itis now prepared upon a plan analogous to that of common in different arts to mold articles from paper-making, involving considerable labor pulp; but in carrying out the process form 35 and complexmachinery. The presentinvening the subject-matter of the present applition obviates these objections to themanucation there is used in every instance a core factu re of laminated sheet-pulp articles,while of some description, which may be of any suitat the same time providing means for conable material, but preferably of wood, on acstrucling a door, shutter, or analogous struccount of the strong adhesive contact that may 4o ture that will be entirely practicaland durabe secured between the same and the pulp ble and also susceptible to a wide range of material forming the main body and exterior ornamentation and decoration, which is only portion of the article. limited by the configuration of the dies and It will be understood that the invention is such foreign matter as may be mixed with not limited to any specific article to be manu- 5 45 the pulp materials to produce any desired refactured; but inasmuch as all articles made suit. 7 by the process have a suitable core to form a TVith these objects in view the present inbase or binder for the pulp material the navention primarily contemplates a novel procture of the invention will be fully understood ess involving steps which provide for moldby referring, for illustrative purposes, to a 5c ing and pressing into shape articles from door, made from pulp materials, manufacpulp materials-such as doors, sh utters, and tured in accordance with the invention. In

the construction of a door from pulp materials by means of the process the core 1 is of the same general configuration as the completed article, being of a rectangular form, as shown in Fig. 7 of the drawings. The said rectangular core 1, though it may be of metal or other suitable material, is preferably constructed of wood, for the reasons explained, and is made in the form of a skeleton framework. Although in some forms of articles made from pulp materials and manufactured by the process the core may be solid or hollow and even imperforate, still in the construction of a door or analogous article with a panel or panels it is necessary to provide the skeleton core 1 with panel-openings 2, which conform in size, shape, and disposition to the panel or panels of the completed article, and as these panel openings entirely pierce the core the same are completely filled by the pulp material, which is molded and pressed upon the core in a manner to be presently explained. By referring particularly to Fig. 8 of the drawings it will be observed that the pulp material forming the body 3 of the door or like structure by being pressed upon the core from both sides thereof not only covers the side faces of the core, but the panel port-ions of the pulp material completely fill the panel opening or openings of the core and produce a solid homogeneous mass of material in said opening or openings, thus pro.- ducing a practically solid structure having exceptional strength and durability.

From the foregoing it will heunderst'ood that it is essentialin the formation of articles from pulp materials by the herein-described process that a suitable interior core be used to form a base or hinder upon which the pulp material may be pressed, and though different forms of apparatus may be utilized to carry the process into effect a preferred 'form is shown in the drawings, to which specific reference will now be made. In the preferred form of apparatus mentioned the same includes a mold-box 4:, which is preferably of a shape con forming to the outlines of the article to be manufactured therein; but ordinarily the said mold-box is of a rectangular shape and essentially consists of a bottom or base 5 and the side and end wallsdand 7, respectively, arising from the said bottom or base 5. The side and end walls 6and 7 of the mold-box are rigidly joined together at their contiguous edges by the corner-postsB, which are fastened to the side and end walls by bolts or other suitable fastenings to form. therein, in connection With-the bottom or base 5, a substantially tight box structure, which is designed to receive therein not only the pulp material and the core of the article, but also the instrumentalities which provide for molding, pressing, and baking the article, so that when the same is removed from the box it is in a practically-finished condition.

Themold-box 4, as already explained, may be of any suitable shape, though the same is preferably of a rectangular form and open at the toptoadmit of the escape of heat, vapor, and any waste product which may result from the baking of the pulp material within the top portion of the box; but in carrying out the invention the end walls 7 of the mold-box are preferably constructed with access-openings 9, which are adapted to be covered and uncovered by swinging end doors 10. Each end door 10 when swung into the opening,

with which it is associated entirely closes that end of the mold-box. To provide for the swinging support of the end doors, each of the same is-provided near one edge and at the upper and lower corners thereof with pintle-studs 11, journaled in suitable bearings 12, fo'rmed in the upper and lower sills of the end walls, and at its free unpivoted edge each door is provided with aplurality of offstanding bifurcated lugs 13, adapted to be engaged and disengaged by the swingbolts 14, fitted to and carried by a rock-shaft 15, journaled in suitable bearings at one edge of the access-opening 9. When. one of they end doors 10 is closed, it is simply necessary to move the adjacent swing-bolts 14 into engagement with the lugs 13 thereof and to tighten said bolts to provide for securely fastening the door in its closed position. A loosening of thebolts and the swinging of the same away from the adjacent edge of the door will permit of the ready opening thereof to provide for either the insertion of the core of the article or the removal of the completed article. It will, be, observed that by reason of this construction of the mold-box with swinging end doors fitted to the opposite end walls thereof simple-and.- efficient means are provided whereby ready access may be had to the interior working spacevof the mold-box through the ends thereof, thus greatly facilitating the handling of the core and the re moval oft-he completed article.

The open-top-mo,ld-box,constructed as de- I scribed, is of a sufficient size to receive therein apair of movable platens 16. These platens conform to the interior shape of the moldbox, the same extending the full length thereof'frorn end to end and being of a width substantially equaling the depth of the box. The said platens are arranged in parallelism to form therebetweena working-space 17, and each of the same is of ahollow formation, being provided therein with a plurality of separate and independent heating-chambers 18, 19, 20, 21, and 22, respectively. In the formof the apparatus shown in the drawings particular reference being made to Fig. 4,

the separate and independent heating-chamand independent flexiblepipe Connection 23 with a common supply-pipe 24 for the heating agent, which may be steam, hot air, or hot water, as may be found the most suitable for the purpose, according to the nature and composition of the pulp material that. may be used in the construction of the article, and each of the flexible pipe connections, which maybe properly termed distributingpipes for the heating agent, is fitted with a controlling-valve 25, which provides means whereby each heating-chamber of the platen may have the heating agent supplied thereto or cut off therefrom independently of the remaining chambers. In addition to the individual supply-pipe connections for the several heating-chambers of each platen such chambers have also connected therewith, preferably at the ends thereof, separate and independent flexible drain-pipe connections 26, leading to the main drain-pipes 27, arranged exterior to the mold-box and providing in connection with the flexible pipes 26 means for draining off from the chambers of the platens such condensed products or waste material as may result from the heating step.

The movable platens 16 in addition to the heating-chain bers thereof are each preferably provided at their ends contiguous to the end walls of the mold-box with packing-strips 28, loosely fitted to the platens in any suitable manner and yieldingly projected beyond the ends thereof by springs 29 or equivalent devices, which provide means for holding the packing-strips yieldingly in contact with the end walls or doors of the mold-box to provide for closing the interstices at this point to prevent leakage of the pulp material while at the same time allowing for the contraction and expansion of the platens without interfering with their proper movement toward and away from each other in the operation of the apparatus. The said platens, which are designed to move toward and away from eachother, have fitted upon their opposing faces suit-able dies 30. These dies may be held to the platens by holding-clips or any suitable means which permit of their ready attachment and removal, and the same are of any desired configuration or design which is to be impressed upon the pulp material. In the construction of doors or analogous structures with a panel or panels the projecting portions of the dies are designed to work into the panel opening or openings of the core and not only press the pulp material through said opening or openings in a solid homogeneous mass, but at the same time impressing upon the pulp material the design or ornamental beading with which such articles are usually provided.

The core 1 of the article which is inserted into the working space 17 between the two platens through the access-opening at either end of the mold-box is designed to be sustained in an upright position between and parallel with the platens, preferably by means of the centering-screws 31, mounted in the end doors 10 of the mold-box and preferably provided with inner point-ed ends 32, adapted to engage with the ends of the core, and thereby hold it in proper position to permit the pulp material to be pressed and molded into shape thereon.

In the operation of the'apparatus it will be necessary to provide for the movement of the platens toward and away from each other, and to secure this movement in a positive manner there are employed pairs of operating-screws 33, arranged, respectively, above and below the platens at the top and bottom of the mold-box, as plainly shown in Figs. 4- and 5 of the drawings. The pairs of operating-screws are swiveled or journaled at opposite sides of the mold-box in suitable bearings 34 and are also provided with separate right and left threaded portions 35, which work in the threaded openings 35 formed in the extremities of the upright carrier-bars 35, to which the platens are suitably fastened, so as to be carried thereby. The operatingscrews 33 are extended beyond one side of the mold-box and are designed to be associated with gearing or any other suitable operating means to provide for turning the same either backward or forward, according to the desired movement to be imparted to the movable platens, and at this point it will be observed that by reason of attaching the platens to the carrier-bars 35 which project above and below the same, there is no interference whatever with the action of the platens upon the material, and the necessity of piercing the platens with threaded openings for the reception of the screws is obviated.

When the screws 33 are turned in one direction, the movable platens 16 will be caused to approach each other, while the turning of the screws in the opposite direction will cause the platens of each pair to recede from each other and away from the article formed therebetween, and it may be observed at this point that the platens may be caused to move at any rate of speed that may he desired and the operation may be stopped during any step of the process and again resumed, as experience and the nature of the material may require. It will furl her be observed that in the preferable construction of the apparatus the inner faces of the end doors and the bottom of the mold-box are planed perfectly true to prevent leakage, the packing-strips 28, already referred to, assisting in securing this desirable result.

In constructing the apparatus it is also desirable to provide means for allowing heat, vapor, and waste material topscape from the edges of the article during the baking thereof. To make provision for this, the bottom or base 5 of the moldbox is provided in the upper side thereof with a longitudinal waste channel or gutter 37, extending from end to end of the bottom and declining toward both ends thereof, so that any waste product or material entering the same may be readily discharged at the ends of the mold-box. The said longitudinal waste channel or gutter 3'7 is arranged in such a position as to be disposed at the bottom of the working space 17, and at its upper open side the said channel or gutter 37 is preferably covered by a perforate coverplate 38, formed of perforated metal, wire-v gauze, or equivalent material. In addition to providing the bottom of the mold-box with the waste channel or gutter 37 the end doors or walls thereof are also provided in their inner faces with longitudinallydisposed waste channels or gutters 39, which are covered by perforate cover-plates 40, similar to the perforate cover-plate 38, and which when the doors are closed communicate with the bottom waste channel or gutter 37, and thereby provide for the complete removal of such waste products or materials as may escape from the edges of the article during the baking process.

In carrying out the process the pulp material used may be wood-pulp material, paperpulp material, or in fact any pulp material that can be utilized for the purpose, and prior to introducing this pulp material into the mold-box such coloring or adhesive ingredicuts as it may be desired to use are mixed therewith. With reference to the use of the adhesive compound it may be explained atthis point that when the same is incorporated into the pulp material it subserves two important functionsfiirst,to cause the material to attach itself more firmly to the core, and, second, to cement the particles of the pulp material firmly together into a homogeneous mass While at the same ti meimparting sm oothness and finish to that part of the pulp material contacting with the faces of the dies. Instead of introducing the adhesive compound or substance directly into the pulp material the same may be applied directly to the core itself prior to the application of the pulp thereto to insure a firmer adherence of the pulp material to the core, and while either of these methods of using the adhesive compound or substance may be resorted to it will be understood that if found expedient or desirable both methods may be utilized at once namely, to introduce the adhesive compound or substance into the pulp material and also to apply the same directly to the core prior to the application of the pulp material.

After having prepared the pulp material the core,which is inserted through one of the end access-openings and supported in place by the centering-screws 31, is completely enveloped with the pulp material, so that the same will fill any interstices or openings with which it may be provided. With the core in position and enveloped by the pulp material heat may be applied to all of the heatingchambers of the platens at one time or to such chambers as may be considered desirable; but a preferable way of carrying out the process isto first admit the heating agent to such heating chambers of each platen through the distributing-pipe connections as are in closest proximity to the densest portions of the pulp materials. This will result in warming up the thickest portions of the pulp materials first, causing the vapor and waste products to work out of the same toward the edges. By then applying the heating agent to the adjoining chambers the vapor and waste products will be still more worked out toward the edges of the article, so that when the heating agent is finally admitted to the uppermost and lowermost heating-chambers of the platens the baking of the article will be thoroughly accomplished. By reason of this operation uneven baking of the material may be obviated and a practically-uniform result obtained,which is very desirable in the construction of such articles as doors and the like In other Words, it is preferable in carrying out the invention to successively apply the heat from the central portion of the article out toward the edges thereof to insure a thorough drying and baking of the same, and in the manufacture of doors and like articles this method of heating will provide for warming up the densest or thickest portions of the pulp material first.

While heat is applied to theplatens through the medium of the heating-chambers and pipe connections described, the adhesive compound added to the pulp material is caused to fuse and harden and the vapor and waste products pass out through the open top of the box, while vapor and other waste products are also permitted to readily escape into the channels 37 and 39. During the baking of the pulp material motion is imparted to the movable platens, which are caused to approach each other gradually until the vapor and waste products have been thoroughly eliminated and the resultant mass is completely baked, and consists of the interior core 1 and the homogeneous body 3, entirely surrounding the same and completely filling any interstices or openings thereof. At the time the platen presses the pulp material upon its core the die-faces or dies 30 thereof will impress upon the surfaces of the pulp material any desired design or ornamentation. l/Vhen the article has thus been-completed, the movable platens are caused to recede from 'the same, so that the article can be readily removed through either end door.

In connection with the construction described it will be observed that the provision of the waste-channels greatly shortens the operation of baking.

After removing the completed article from the mold-box if a higher degree of finish is desired than may be obtained in the process just described the article may be placed in any ordinary stamping-press with dies and by the action of pressure or heat, or both, may be given a still. more attractive and durable finish. susceptible to decoration or embellishment The article of-course is also by paints, stains, varnishes, or other wellknoWn means.

From the foregoing it is thought that the essential steps of the herein-described process will be readily understood by those skilled in the art without further description, and it will be understood that any changes which do not affect the result accomplished by these steps may be resorted to without departing from the spirit or sacrificing any of the advantages of the invention.

The apparatus described herein forms no part of the present application, as the same constitutes the subject-matter of my companion application, Serial No. 736,277, patented August 28, 1900, No. 656,742.

Having thus described the invention, what is claimed as new, and desired to be secured by Letters Patent, is-

1. A process for making articles having a permanent interior core having openings and a body portion of pulp material, the same consisting in applying pressure of the same degree simultaneously to opposite sides of the pulp material, and forcing the opposite portions thereof into homogeneous union through the openings in the core and also upon the faces of the same, subjecting the pulp material to heat during the application of the pressure, and molding surface ornamentation upon both faces of the article simultaneously with the application of the heat and pressure.

2. A process for making articles from pulp materials having thinner and denser portions which consists in applying pressure to the body of material to form the said article, and simultaneously applying heat successively from the denser to the thinner portions thereof.

3. A process for making articles having a permanent interior core and a body portion of pulp material having thinner and denser portions, the same consisting in simultaneously applying pressure of the same degree to opposite sides of the material to form the said article, successively applying heat from the denserto the thinner portions of the material, and molding and pressing the material upon its core during the successive application of the heat.

45. A process for making articles having a permanent interior core and a body portion of pulp material,the same consistingin applying pressure of the same degree simultaneously to opposite sides of the pulp material and forcing the opposite portions thereof compactly upon the faces of the core causing a positive and permanent adhesion of the pulp material to the core, subjecting the pulp material to heat during the application of the pressure, and molding surface ornamentation upon both faces of the article simultaneously with the application of the heat and pressure.

5. A process for making articles having a permanent interior core and a body portion of pulp material adhesively united thereto, the same consisting in applying pressure to the body of pulp material to press the same upon the core, and simultaneously applying heat successively from the central portion of the article toward the edges thereof.

In testimony that I claim the foregoing as my own I have hereto affiXed my signature in the presence of two Witnesses.

JAMES MARSHALL LEAVER.

Witnesses:

WM. M. DRAKE, WM. H. FULLER. 

